Direct write interconnections and method of manufacturing thereof

1. A method of forming a device package comprising: providing a substrate structure; attaching at least one device to the substrate structure such that the at least one device extends outwardly from a surface of the substrate structure, each of the at least one device including a substrate and at least one connection pad formed on the substrate; depositing a dielectric layer over the at least one device and onto the substrate structure by way of a direct write application, the dielectric layer including vias formed therethrough; forming an interconnect structure on the dielectric layer that is electrically coupled to the at least one connection pad of the at least one device, the interconnect structure extending through the vias in the dielectric layer so as to be connected to the at least one connection pad; filling the vias with a via fill material; and curing the fill material; wherein the fill material enhances the electrical, thermal, or mechanical properties of the interconnect structure.

2. The method of claim 1 wherein depositing the dielectric layer by way of the direct write application comprises selectively depositing dielectric material at desired locations.

3. The method of claim 2 wherein the selective depositing of dielectric material at the desired locations leaves openings in the dielectric layer, the openings forming the vias.

4. The method of claim 2 wherein the dielectric material is selectively deposited using at least one of an ink jet printer application, dispensing, laser writing, or printing technique, or a combination thereof.

5. The method of claim 1 wherein the at least one device comprises a plurality of devices, the plurality of devices including at least one of a die, diode, power electronic device, and a passive device.

6. The method of claim 5 wherein the plurality of devices have differing thicknesses so as to extend out from the substrate structure at a plurality of different heights.

7. The method of claim 5 wherein the dielectric layer is deposited by way of the direct write application so as to conform three dimensionally to and about the plurality of devices and so as to at least partially fill in gaps present between the plurality of devices in all three dimensions.

8. The method of claim 1 wherein forming the interconnect structure comprises: applying a seed layer of metal material via a sputtering or evaporation process; and electroplating additional metal material to the seed layer; and patterning the metal material to form the interconnect structure.

9. The method of claim 1 wherein forming the interconnect structure comprises applying metal material by way of a direct writing application to form metallic traces within the vias down to the at least one connection pad and on the dielectric layer.

10. The method of claim 9 wherein the metal material applied by way of the direct writing application forms a seed layer, and wherein the method further comprises plating an additional metal material onto the seed layer to form the interconnect structure.

11. The method of claim 1 further comprising: depositing an additional dielectric layer over the dielectric layer and interconnect structure by way of a direct write application; and forming an interconnect structure on the additional dielectric layer.

12. A method of manufacturing a semiconductor device package comprising: providing a substrate structure; attaching at least one semiconductor device to the substrate structure, each of the at least one semiconductor device including a substrate composed of a semiconductor material and at least one connection pad formed on the substrate; direct writing a dielectric material onto the at least one semiconductor device and onto the substrate structure so as to form a conformal dielectric layer, the dielectric material being selectively deposited via the direct writing so as to form one or more via openings in the conformal dielectric layer at locations corresponding to the at least one connection pad; forming an interconnect structure on the conformal dielectric layer that is electrically coupled to the at least one connection pad of the at least one semiconductor device, the interconnect structure extending through the via openings in the dielectric layer so as to be connected to the at least one connection pad; filling the vias with a via fill material; and curing the material; wherein the via fill material enhances the electrical, thermal, or mechanical properties of the interconnect structure.

13. The method of claim 12 wherein the dielectric material is selectively deposited via direct writing using at least one of a jetting, dispensing, laser writing, or printing technique, or a combination thereof ink jet printer application.

14. The method of claim 12 wherein forming the interconnect structure comprises: applying a seed layer of metal material via a sputtering or evaporation process; plating additional metal material to the seed layer; and patterning the metal material to form the interconnect structure.

15. The method of claim 12 wherein forming the interconnect structure comprises direct writing a metal material to form metallic traces within the vias down to the at least one connection pad and on the conformal dielectric layer.

16. The method of claim 15 wherein the metal material applied by way of the direct writing application forms a seed layer, and wherein the method further comprises plating an additional metal material onto the seed layer to form the interconnect structure.

17. The method of claim 12 further comprising: direct writing an additional conformal dielectric layer over the dielectric layer and interconnect structure; and forming an interconnect structure on the additional conformal dielectric layer.

18. A semiconductor device package comprising: a substrate structure; semiconductor devices attached to the substrate structure, with each of the semiconductor devices including a substrate composed of a semiconductor material and one or more connection pads formed on the substrate; a conformal dielectric layer formed over and around the semiconductor devices, the conformal dielectric layer including one or more vias formed therethrough; an interconnect structure electrically coupled to the plurality of connection pads of the semiconductor devices, the interconnect structure extending through the vias formed through the conformal dielectric layer so as to be connected to the connection pads; and a fill material filled into the vias, the fill material being cured so as to enhance the electrical, thermal, or mechanical properties of the interconnect structure; wherein the conformal dielectric layer is applied via a direct write application such that the dielectric layer conforms to the semiconductor devices and fills in gaps present between the semiconductor devices.

19. The semiconductor device package of claim 18 wherein the interconnect structure comprises a plurality of metallic traces applied via a direct write application.

20. The semiconductor device package of claim 18 further comprising a via fill material deposited in the vias.

21. The semiconductor device package of claim 18 further comprising: an additional dielectric layer positioned over the dielectric layer and the interconnect structure by way of a direct write application, the additional dielectric layer being applied via a direct write application such that the dielectric layer is configured as a conformal dielectric layer; and an interconnect structure formed on the additional dielectric layer.

22. The semiconductor device package of claim 18 wherein the semiconductor devices have differing thicknesses so as to extend out from the substrate structure at a plurality of different heights, and wherein the conformal dielectric layer conforms to the semiconductor devices of differing thicknesses.